US6090335A - Process of forming fiber reinforced composite articles using an insitu cured resin infusion port - Google Patents
Process of forming fiber reinforced composite articles using an insitu cured resin infusion port Download PDFInfo
- Publication number
- US6090335A US6090335A US09/227,461 US22746199A US6090335A US 6090335 A US6090335 A US 6090335A US 22746199 A US22746199 A US 22746199A US 6090335 A US6090335 A US 6090335A
- Authority
- US
- United States
- Prior art keywords
- resin
- infusion port
- fiber
- mold surface
- reinforced
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
- B29C70/546—Measures for feeding or distributing the matrix material in the reinforcing structure
- B29C70/547—Measures for feeding or distributing the matrix material in the reinforcing structure using channels or porous distribution layers incorporated in or associated with the product
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
- B29C43/3642—Bags, bleeder sheets or cauls for isostatic pressing
- B29C2043/3644—Vacuum bags; Details thereof, e.g. fixing or clamping
Definitions
- the present invention relates generally to fiber-reinforced resin structures, and more particularly to a process of fabricating a fiber-reinforced resin structure using a resin infusion port which is cured in place.
- VARTM Vacuum assisted resin transfer molding
- Such articles may include coach chassis for buses and trailers and fiber glass boat hulls, for example.
- the VARTM process includes the distribution of dry, fiber strips, plies or mats about the surface of a female mold to form a fiber lay-up of a desired thickness.
- the fiber strips or plies may take the form of a cloth or sheet of fibers of glass, carbon or other suitable material.
- one or more rigid core layers may be included.
- the core layers may be formed of a solid foam material or balsa wood.
- the core layers may be sandwiched between the fiber plies to form a fiber/core composite lay-up or laminate.
- a flexible, fluid impermeable bag or sheet is positioned atop the exposed lay-up and sealed about the periphery thereof.
- a relative vacuum is drawn between the mold and the bag, thereby causing the bag to compress against the fiber lay-up.
- a chemically catalyzed liquid resin is introduced into the evacuated bagged mold through a series of resin supply lines or conduits.
- a multitude of individual resin supply lines may be used so as to facilitate distributed wetting or infusion of the liquid resin about the fiber lay-up.
- the vacuum source and resin supply lines are strategically positioned relative to one another in a manner which encourages controlled wetting. In this respect, the vacuum source may be applied at one side of the fiber lay-up and the resin introduced at an opposing side, and thus tending to cause the resin to be pulled across and wet portions of the fiber lay-up therebetween.
- Contemporary techniques for facilitating more uniformed or homogeneous resin distribution include the use of cloth material adjacent the fiber lay-up.
- the cloth forms a screen or matrix of open spaces which tends to wick the resin, and thereby facilitates resin flow.
- the cloth is removed or peeled away prior to the resin fully curing.
- Other techniques for enhancing more uniformed resin distribution focus on the resin delivery apparatus, such as specially formed resin supply conduit manifolds and manifolds which are integrated into the vacuum bag itself. While these and other techniques enhance the distribution of resin about the fiber lay-up, they each require the positioning and application of a particular type of cloth or conduit manifold or the like, each time the article is formed.
- specialized procedures for disposal and/or clean-up of such additional apparatus must be addressed as well. As such, use of such apparatus increases the time and skill requirements in order to fabricate a resultant article to desired quality control standards.
- a process for forming a fiber-reinforced resin structure having an opening therein by vacuum bag forming A resin infusion port is disposed adjacent a mold surface.
- the resin infusion port has a resin inlet and at least one resin outlet.
- a fiber-reinforced ply is distributed adjacent the mold surface about the resin infusion port.
- a flexible covering is placed over the fiber-reinforced ply and the mold surface to form a chamber therebetween.
- the chamber is evacuated.
- Resin is dispensed into the resin infusion port through the resin inlet.
- the resin is infused into the ply by dispensing resin into the chamber from the resin infusion port through the resin outlet.
- the resin is cured within the resin infusion port and within the chamber to form a cured resin structure which is subsequently removed from the mold surface.
- An opening is formed in the resin structure by removing the resin infusion port and a portion of the resin structure adjacent the resin infusion port.
- An example of an opening being required to be formed in a fiber-reinforced resin structure is at the wheel well portion of a bus coach lower chassis for extension of a shock absorber and other structural supports or linkages therethrough.
- a typical method of forming such an opening is to form a fiber-reinforced resin structure in whole, and subsequently drill or cut an opening therein at the desired location.
- the method of the present invention for fabricating fiber-reinforced resin structures having an opening formed therein presents numerous advantages not found in the related prior art.
- the present method incorporates or integrates the infusion port into the structure itself, thereby facilitating direct infusion or distribution of liquid resin into and about the adjacent fiber-reinforced plies.
- the present invention is particularly adapted to provide enhanced resin distribution by use of a cured in place or insitu resin infusion port.
- Such enhanced resin distribution tends to increase the structural integrity of the resultant fiber-reinforced resin structures. This is particularly advantageous as such locations are typically highly susceptible to the development of stress concentrations thereat.
- the present method enhances resin distribution, the time and skill requirements to fabricate the resultant fiber-reinforced structure is reduced. As such, the resultant structures can be produced at rates which make the technology more economically viable.
- the present invention represents an advance in the art.
- FIG. 1 is a perspective view of a mold for use in conjunction with the process of the present invention
- FIG. 2 is a enlarged perspective view of a portion of the mold of FIG. 1 shown with a bagged fiber-reinforced lay-up and resin infusion ports used in conjunction with the process of the present invention
- FIG. 3 is a cross-sectional view of the bagged mold and resin infusion port of the present invention
- FIG. 4 is a cross-sectional view of the bagged mold of FIG. 3 shown with a resin supply hose;
- FIG. 5 is a cross-sectional view of the bagged mold of FIG. 4 shown with resin being infused into fiber-reinforced lay-up;
- FIG. 6 is a cross-sectional view of the mold of FIG. 5 shown with a resultant cured fiber-reinforced lay-up after being removed from the mold;
- FIG. 7 is a cross-sectional view of the cured fiber-reinforced lay-up after having an opening formed therein.
- FIGS. 1-7 illustrate a process for forming a fiber-reinforced resin structure having an opening therein by vacuum bag forming.
- the mold 10 defines a mold cavity 12 and having a mold surface 14.
- the mold 10 is sized and configured to conform to the shape of desired resultant product.
- the mold 10 is symbolically representative.
- the mold 10 is depicted to conform to the geometry of a bus lower chassis and is therefore provided with wall, floor and wheel well portions 16, 18, 20.
- the mold surface 14 has regions which are aligned to be horizontal, vertical and at other angular orientations. Further, it is contemplated that the mold surface 14 may have generally planar portions as well as those which or curved or irregularly shaped.
- the VARTM process of forming fiber-reinforced resin structures typically begins with the distribution of fiber-reinforced plies 22 and core material 24 about the mold surface 14.
- the fiber-reinforced plies 22 take the form of a cloth or sheet of fibers of glass, carbon or other suitable materials which are well known to one of ordinary skill in the art.
- one or more rigid core layers 24 may be included.
- the core layers 24 may be formed of a solid foam material, balsa wood or other suitable materials which are well known to one of ordinary skill in the art.
- the core layers 24 may be sandwiched between the fiber-reinforced plies 22 to form a fiber/core composite lay-up or laminate.
- the fiber-reinforced plies 22 form a solid fiber or solid glass section thereat.
- the fiber-reinforced plies 22 and core layers 24 are applied to a desired thickness. It is contemplated that the mold 10 and mold surface 14 are of such structural integrity so as to be supportive the fiber-reinforced plies 22 and core layers 24.
- the typical VARTM process further provides for a flexible, fluid impermeable bag or covering 26 is positioned atop the topmost fiber-reinforced ply 22.
- the periphery of the covering 26 is sealed against the mold surface 14 thereby bagging the fiber-reinforced plies 22 and core layers 24 therein.
- a chamber 28 is formed between the covering 26 and the mold surface 14.
- a relative vacuum is drawn within the chamber 28 (i.e., between the mold 10 and the covering 26), thereby causing the covering 26 to compress and collapse against the fiber lay-up, according to those methods which are well known to one of ordinary skill in the art.
- vacuum conduits 30 may be selectively distributed about the mold 10.
- the vacuum conduits 30 may be disposed through the covering 26 or at the periphery thereof and sealed therewith via vacuum manifold 32.
- the vacuum conduits 30 are in vacuum communication with a vacuum source 34 and supporting vacuum lines 36.
- a chemically catalyzed liquid resin is pumped from a resin source 38 through a series of resin supply lines 40 which are selectively distributed about the mold 10.
- a multitude of individual resin supply lines 40 may be used so as to facilitate distributed wetting or infusion of the liquid resin about the fiber reinforced plies 22.
- the resin, resin supply lines 40 and supporting pumping apparatus are contemplated to be chosen from those which are well known to one of ordinary skill in the art.
- some of the resin supply lines 40 terminate at a topically-mounted resin delivery apparatus 42.
- the topically-mounted resin delivery apparatus 42 may be disposed through the covering 26 or at the periphery thereof and in sealed communication therewith according to those methods which are well known to one of ordinary skill in the art.
- a resin infusion port 44 is disposed adjacent the mold surface 14.
- the resin infusion port 44 has an resin inlet 46 for receiving resin therethrough and at least one resin outlet 48 for dispensing resin therethrough.
- the vacuum conduits 30, the topically-mounted resin delivery apparatus 42 and the resin infusion port 44 are strategically and cooperatively positioned relative to one another in a manner which encourages controlled resin wetting.
- the vacuum ports 32 may be applied at one portion of the mold 10 and the topically-mounted resin delivery apparatus 42 at another portion. The relative positioning of the vacuum ports 32 and the topically-mounted resin delivery apparatus 42 tends to cause the dispensed liquid resin to be pulled across and wet portions of the fiber-reinforced plies 22 therebetween.
- a resin infusion port 44a is disposed adjacent the floor portion 18 of the mold 10 and another resin infusion port 44b is disposed adjacent the wheel portion 20 of the mold 10.
- the fiber-reinforced plies 22 may be interleaved with one or more core layers 24 such as is depicted adjacent the floor portion 18 of the mold 10. It is also contemplated that the fiber-reinforced plies 22 may not be accompanied by any core layers 24 as may be the case adjacent the wheel well portion 20 of the mold 10. As such, the resin infusion ports 44 may be disposed adjacent fiber-reinforced plies 22 having or not having any core layers 24.
- the resin infusion port 44 preferably takes the form of a cap-like structure and is generally defined by a central axis of symmetry which extends through the resin inlet 46.
- the resin outlets 48 are formed to extend from the central axis and radially distributed thereabout.
- the resin infusion port 44 is sized and configured such that central axis is disposed orthogonal to the mold surface 14.
- the resin outlets 48 may be variably distributed along the central axis such that the resin outlets are differentially displaced from the adjacent mold surface 14.
- Such variable distribution of the resin outlets 48 is contemplated to align the resin outlets adjacent different portions of the fiber/core lay-up (i.e., fiber-reinforced plies 22 and core layers 24).
- variable distribution of the resin outlets 48 facilitates ease of resin distribution to selective fiber-reinforced plies 22.
- a resin supply line 40 is engaged with the resin inlet 46.
- the resin supply line 40 and resin inlet 46 are cooperatively formed to facilitate such engagement.
- the chamber 28 formed between the covering 26 and the mold surface 14 is evacuated.
- Resin 50 is pumped from the supply line 40 through the resin inlet 46 into the resin infusion port 44.
- the resin 50 is consequently dispensed therefrom through the resin outlets 48 and into and about the chamber 28.
- the resin 50 is infused into the adjacent fiber-reinforced plies 22.
- the pumping of the resin 50 is ceased and the resin supply line 40 is disengaged from the resin infusion port 44.
- the infused fiber-reinforced plies 22 and core layer 24 are allowed to cure according to those methods which are well known to one of ordinary skill in the art.
- the resin infusion port 44 is thus secured in place or insitu relative to the fiber-reinforced plies 22 and core layer 24.
- the resultant fiber-reinforced resin structure 54 is removed from the mold 10. It is contemplated that in order to facilitate ease of such removal, a gelcoat of suitable material known to those of ordinary skill in the art may be applied to the mold 10.
- an opening 52 is formed therein by cutting or otherwise machining that portion of the fiber-reinforced structure 54 surrounding the insitu resin infusion port 44, as depicted in FIG. 7. Subsequently, it is contemplated that the resin infusion port 10 may be simply discarded as waste material. As such the resin infusion port 44 may be formed of a relatively inexpensive molded plastic material. It is contemplated, however, the resin infusion port 44 may be cleaned of cured resin 50 and any remaining fragments of the fiber-reinforcement plies 22 and/or core layer 24 for later reuse.
Abstract
Description
Claims (3)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/227,461 US6090335A (en) | 1999-01-08 | 1999-01-08 | Process of forming fiber reinforced composite articles using an insitu cured resin infusion port |
AU24029/00A AU2402900A (en) | 1999-01-08 | 2000-01-03 | Process of forming fiber reinforced composite articles using an insitu cured resin infusion port |
PCT/US2000/000035 WO2000040387A1 (en) | 1999-01-08 | 2000-01-03 | Process of forming fiber reinforced composite articles using an insitu cured resin infusion port |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US09/227,461 US6090335A (en) | 1999-01-08 | 1999-01-08 | Process of forming fiber reinforced composite articles using an insitu cured resin infusion port |
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US6090335A true US6090335A (en) | 2000-07-18 |
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US09/227,461 Expired - Lifetime US6090335A (en) | 1999-01-08 | 1999-01-08 | Process of forming fiber reinforced composite articles using an insitu cured resin infusion port |
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AU (1) | AU2402900A (en) |
WO (1) | WO2000040387A1 (en) |
Cited By (34)
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US6406660B1 (en) * | 2000-02-07 | 2002-06-18 | The United States Of America As Represented By The Secretary Of The Army | Method for producing polymer matrix composites having low volume percentage of reinforcement fiber and controlled thickness |
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EP1235672B1 (en) * | 1999-12-07 | 2005-03-02 | The Boeing Company | Double bag vacuum infusion process for manufacturing a composite and composite obtained thereby |
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US20150014883A1 (en) * | 2012-02-15 | 2015-01-15 | Toray Industries, Inc. | Method of manufacturing fiber-reinforced resin |
US8936695B2 (en) | 2007-07-28 | 2015-01-20 | The Boeing Company | Method for forming and applying composite layups having complex geometries |
US9387657B2 (en) | 2010-11-12 | 2016-07-12 | The Boeing Company | Method of fabricating a curved composite structure using composite prepreg tape |
US9701067B2 (en) | 2010-11-12 | 2017-07-11 | The Boeing Company | Method of laying up prepreg plies on contoured tools using a deformable carrier film |
US9770871B2 (en) | 2007-05-22 | 2017-09-26 | The Boeing Company | Method and apparatus for layup placement |
US20190145697A1 (en) * | 2017-01-18 | 2019-05-16 | Whirlpool Corporation | Use of multiple port locations for achieving faster vacuum evacuation time in vacuum insulated structures |
US11029080B2 (en) | 2017-01-18 | 2021-06-08 | Whirlpool Corporation | Use of rigid or permeable conduits for achieving faster vacuum evacuation time in vacuum insulated structures |
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